Fluid and heat resistant chlorinated polyethylenes (cpe)

ABSTRACT

A chlorinated rubber composition which is resistant to various fluids such as transmission fluids comprises a blend of a chlorinated polyethylene elastomer, an ethylene acrylic elastomer and/or polyacrylic rubbers, and optionally a chlorosulfonated polyethylene. The rubber composition has many uses such as a tube and generally contains various additives such as fillers, plasticizers, vulcanizing agents, and the like. 
     A heat resistant rubber composition comprises a blend of a chlorinated polyethylene elastomer, an ethylene-acrylic elastomer and/or polyacrylic rubbers, an ethylene-octene copolymer, and an ethylene-propylene-diene terpolymer, and the same can be used as a cover or jacket as on the above chlorinated rubber tube.

FIELD OF THE INVENTION

The present application relates to chlorinated polyethylene rubbercompositions which have good fluid resistance, e.g. automatictransmission fluids, or have good high heat resistance.

BACKGROUND OF THE INVENTION

Heretofore, numerous rubber compounds were utilized as sheets, tubings,liners, and the like. However, generally no chlorinated polyethylenerubber compositions have existed which had good resistance totransmission fluids, especially the recent new types of ‘E-fluids’.

Similarly, while numerous types of high temperature-resistant rubberswere available, generally no blend of a chlorinated polyethyleneelastomer, an ethylene-octene copolymer, and an ethylene-acrylic and/ora polyacrylic elastomer was known which had good heat resistance as atapproximately 150° C.

SUMMARY OF THE INVENTION

Fluid resistant rubbers generally comprise 70 parts by weight ofchlorinated polyethylene, and about 5 to about 49 parts by weight of anethylene-acrylic elastomer having a Mooney viscosity (ML 1+4/100° C.) ofabout 10 to about 25 and/or a polyacrylic elastomer having a Mooneyviscosity of from about 10 to about 70.

Rubber compositions having good high heat resistance generally comprise70 parts by weight of a chlorinated polyethylene rubber containing fromabout 25% to about 45% chlorine by weight, from about 5 to about 49parts by weight of an ethylene-octene copolymer having an octene contentof from about 25% to about 55% by weight, from about 5 to about 49 partsby weight of an ethylene-acrylic elastomer having a Mooney viscosity offrom about 10 to about 25 and/or an polyacrylic rubber having a Mooneyviscosity of from about 10 to about 70, and optionally from about 10 toabout 50 parts by weight of an EPDM rubber containing from about 30% toabout 70% by weight of ethylene repeat units and from about 0.1% toabout 8% of diene repeat units.

DETAILED DESCRIPTION OF THE INVENTION Fluid Resistant RubberCompositions

The various components of the chlorinated rubber composition are basedupon 70 parts by weight of at least one chlorinated polyethyleneelastomer. The chlorinated elastomer generally contains from about 25%to about 50% by weight, desirably from about 30% to about 45% by weight,and preferably from about 36% to about 42% by weight of chlorinetherein. Examples of suitable chlorinated polyethylene elastomers areknown to the literature and to the art and specific commercial examplesof such compounds include Tyrin CM 0836 which contains approximately 36%by weight of chlorine and has a Mooney viscosity (ML 1+4/100° C.) ofabout 100, Tyrin CM 0136 which contains approximately 36% by weight ofchlorine and has a Mooney viscosity of about 80, and Tyrin CM 4211Pwhich contains approximately 42% by weight of chlorine and has a Mooneyviscosity of about 80. All of the Tyrin chlorinated polyethyleneelastomers are available from DuPont Dow.

Whenever reference is made to a Mooney viscosity in the presentinvention it is an (ML1+4/100° C.) Mooney viscosity.

An important aspect of the chlorinated polyethylene elastomers of thepresent invention is that they are desirably curable by peroxides suchas those set forth herein below, as well as by various thio compoundssuch as thiadiazole derivatives, and also by irradiation. If two or morechlorinated polyethylene elastomers are utilized, the range of any oneelastomer can generally be from about 1% to about 99% by weight anddesirably from about 25% to about 75% by weight based upon the totalweight of all of the chlorinated polyethylene elastomers.

Another important component of the chlorinated rubber composition is atleast one ethylene-acrylic elastomer wherein the acrylic can be an alkylacrylate wherein the alkyl portion desirably has from about 1 to about 8carbon atoms and preferably is methyl acrylate. The ethylene-acrylicelastomer generally has a Mooney viscosity of from about 10 to about 25and desirably from about 13 to about 19. The total amount of the one ormore ethylene-acrylic elastomers is generally from about 5 to about 49parts, desirably from about 5 to about 40 parts, and preferably fromabout 25 to about 35 parts by weight per 70 parts by weight of said oneor more chlorinated polyethylene elastomers Examples of suitableethylene-acrylic elastomers include the various Vamac elastomersavailable from DuPont Industrial Polymers such as Vamac D, Vamac DLS,Vamac G, Vamac GLS, and Vamac HG with Vamac DP being highly preferred.

In lieu of the ethylene-acrylic elastomer or in any portion therewith,one or more polyacrylate elastomers can be utilized which are known tothe art and to the literature. Generally, polyacrylate elastomerscontain repeat units of alkyl acrylates wherein the alkyl portiondesirably has from 1 to about 8 carbon atoms, and preferably is methylacrylate or ethyl acrylate. Generally lesser amounts of alkoxy acrylatesare also utilized wherein the alkoxy portion generally has from 1 to 5carbon atoms with methoxy or ethoxy being preferred. The Mooneyviscosity of the one or more acrylate elastomers is generally from about10 to about 70 and preferably from about 25 to about 40 or 55. Theamount of the polyacrylic elastomers is generally from about 5 to about49 parts, desirably from about 5 to about 40 parts, and preferably fromabout 25 to about 35 parts by weight per 70 parts by weight of saidchlorinated polyethylene elastomers. The polyacrylic elastomer can beutilized either in lieu of the one or more ethylene-acrylic elastomersor partially substituted therefore. In other words, any combination ofthe ethylene-acrylic elastomers or the polyacrylic elastomers can beutilized with the total amount of both being from about 5 to about 49parts by weight, desirably from about 5 to about 40 parts by weight andpreferably from about 25 to about 35 parts by weight per 70 parts byweight of said polychlorinated polyethylene elastomers. Inasmuch as thepresent invention generally relates to peroxide curer polyacrylates areutilized which are curable by a peroxide. Since the polyacrylates have asaturated backbone, crosslinking is accomplished via incorporation of acopolymerized reactive cure site such as through the use of suitableperoxide reactive compounds such as a carboxylic acid, and the like. Asuitable polyacrylic elastomer is HyTemp PV-04 made by Zeon Chemicals.

An optional but desired component of the chlorinated rubber compositionis a chlorosulfonated polyethylene which generally contains from about25% to about 45%, desirably from about 30% to about 40% and preferablyfrom about 33% to about 38% by weight of chlorine therein. The amount ofsulfur is generally very low as from about 0.25% to about 2%, desirablyfrom about 0.5% to about 1.5%, and preferably from about 0.75% to about1.25% by weight based upon the total weight of the chlorosulfonatedpolyethylene. One or more chlorosulfonated polyethylenes when utilizedis generally from about 5 to about 49 parts by weight, desirably fromabout 10 to about 40, and preferably from about 25 to about 35 parts byweight per 70 parts by weight of said one or more chlorinatedpolyethylene elastomers. Examples of such suitable compounds include thevarious Hypalon compounds from DuPont Dow such as Hypalon 20, Hypalon30, with Hypalon 40 being preferred which contains approximately 35%chlorine by weight and approximately 1% sulfur by weight.

The chlorinated rubber composition of the present invention iscompounded utilizing generally conventional additives known to the artand to the literature such as activators and/or acid scavengers,processing aids, various fillers which can also serve as reinforcingaids, plasticizers, vulcanizing compounds such as various peroxides,co-agents such as curing activators, lubricants, stabilizers, and thelike.

Activators and/or acid scavengers include various metal hydroxyls and/orcarbonates such as magnesium aluminum hydroxy carbonate, metal oxidessuch as magnesium dioxide, lead oxide, organic lead bases, and the like.A preferred activator/acid scavenger is Maglite D or DE produced by theC. P, Hall Company. The total amount of such activator and/or acidscavenger(s) is generally low such as from about 3 to about 20 anddesirably from about 5 to about 15 parts by weight per 70 parts byweight of said one or more chlorinated polyethylene elastomers.

Processing aids include various waxes such as low molecular weightpolyethylene waxes, polystyrene waxes, paraffin wax, fatty acids, andthe like with the polyethylene waxes being preferred. Suitable amountsof processing aid(s) generally range from about 0.1 to about 10 anddesirably from about 1 to about 5 parts by weight per 70 parts by weightof said one or more chlorinated polyethylene elastomers.

Suitable fillers include Kaolin clay, mica, calcium, carbonate, and thelike. The amount of said filler(s) is generally from about 5 to about 80parts by weight per 70 parts by weight of said one or more chlorinatedpolyethylene elastomers. Reinforcing fillers such as carbon blackpreferably have high surface area and iodine numbers of from about 25 toabout 32. Specific examples include an N762, N774, N550, and N990produced by Cancarb. The amount of the reinforcing agent(s) is generallyhigh as from about 50 to about 300 parts by weight, desirably from about100 to about 250 parts by weight, and preferably from about 125 to about200 parts by weight per 70 parts by weight of said one or morechlorinated polyethylene elastomers.

Numerous types of plasticizers can be utilized to impart heat and lightstability such as one or more epoxidized soybean oils, variousdiphthalates such as diallyl phthalate, di-2-ethylhexyl phthalate,diisopropyl phthalate, linear C₈-C₁₀ phthalates, and linear C₇-C₁₁phthalates; various trimellitates such as tri-2-ethylhexyl trimellitate,trilsooctyl trimellitate, and triisononyl trimellitates; variousadipates such as diisooctyl adipate, di-2-ethylhexyl adipate, diisononyladipate, and diisodecyl adipate; various azelates such asdi-2-ethylhexyl azelate; various glutarates such as diisodecylglutarate; and various sebacates such as di-2-ethylhexyl sebacate. Thetotal amount of the one or more different types of plasticizer(s) isgenerally from about 1 to about 60 parts by weight and desirably fromabout 7 to about 50 parts by weight per 70 parts by weight of said oneor more chlorinated polyethylene elastomers.

The vulcanizing compound is desirably a peroxide and numerous typesthereof are known to the art and to the literature. Examples of suitableperoxides include 4,4-bis(tert-butyl peroxy) butyl valerate, t-butylperbenzoate, 2,5-dimethyl-2,5-di(t-butylperoxy)-3-hexyne,n-butyl-4,4-bis(t-butylperoxy)valerate,1,1-bis(t-butylperoxy)3,3,5-trimethyl cyclohexane,di-(2-tert-butylperoxyisopropyl)benzene, dibenzoyl peroxide,2,5-dimethyl-2,5-di(t-buylperoxy)hexane, dicumyl peroxide, andcombinations thereof. Preferred peroxides include2,2′-bis(tert-butylperoxyd iisopropylbenzene) and1-1-di(tert-butylperoxy)-3,3,5-trimethylcyclhexane availablerespectfully as Vulcup 40KE and Trigonox 20-40B-PD both of which areavailable from Harwick Standard. A total amount of the one or morevulcanizing compounds is generally from about 0.1 to about 10 anddesirably from about 3 to about 6 parts by weight per 70 parts by weightof said one or more chlorinated polyethylene elastomers.

Co-agents generally include two types with Type I serving to improvestate of cure and also rate of reaction whereas Type II generally onlyaffects state of cure. Examples of suitable Type I co-agents includemethacrylate products such as, trimethylolpropane trimethacrylate(TMPTMA), and various Bis-maleimides such as N,N′-m-phenylenedimaleimide (HVA-2), and various acrylates such as trimethylolpropanetriacrylate (TMPTA). Suitable Type II co-agents include triallylcyanurate (TAC), triallyl isocyanurate (TAIC), diallyl terephthalate,and 1,2-Vinyl polybutadienes (Ricons), and the like, Numerous otherco-agent exist and the same are known to the art and to the literature.The total amount of the one or more coagents is generally from about 0.1to about 15 parts by weight and desirably from about 3 to about 12 partsby weight per 70 parts by weight of said one or more chlorinatedpolyethylene elastomers.

The above various compounds and components are compounded andsubsequently formed into desired end use shapes such as a tube. Morespecifically, a desired compounding process involves mixing all of thenon-curing compounds (other than vulcanizing agents and co-agents) inany order in a continuous high shear mixer with the one or more polymersbeing added last. Thus, in any order, the one or more activators and/oracid scavengers, the one or more processing aids, the one or morefillers such as a reinforcing filler, and the one or more plasticizersare added singly in any order with continuous mixing until all of themhave been added and blended in a high shear mixer. Generally any highshear mixer is suitable and a Thyssen Krupp GK 250 E was utilized in thefollowing examples. After all the various additives have been added andmixed, the polymers, that is the one or more chlorinated polyethyleneelastomers, the one or more optional chlorosulfinated polyethylenes, andthe one or more ethylene-acrylic elastomers are added generally in anyorder and mixed until generally a homogenius blend is obtained. Thecompounded rubber can then be cooled in any manner and deposited as aslab which desirably has an anti-crack agent on the surface thereof.When desired, the compounded chlorinated rubber composition of thepresent invention in then added to a high shear mixing device which canbe the same or different as utilized in the formation of the compoundedrubber and is mixed with the one or more vulcanizing agents and one ormore co-agents at a low temperature so that the composition is notcured. The compounded rubber containing the curing additives can beformed into any desired shape such as a tube utilizing an extruder. Thechlorinated rubber compositions of the present invention generally havea good shelf life as from about 35 to about 45 days whereby they can betransferred to an end fabricator and cured at suitable temperatures.

Suitable end forms include sheets, tubes, hoses, and seals. A desiredend use of the chlorinated rubber compositions of the present inventionare as a hose or a tube for use in conveying vehicle transmission fluidsand especially E-type transmission fluids inasmuch as the compoundedrubbers have good resistance thereto. An automatic transmission “E”fluid specification is WSA-M96D26-A of the Ford Motor Company. Suchspecification is hereby substantially reproduced as follows:

Hose, Reinforced Rubber, Automatic WSA-M96D26-A Transmission FluidResistant

1. Scope

This specification defines a straight or formed synthetic rubber hosereinforced with a single ply of braided textile, with good resistance toautomatic transmission fluid.

2. Application

This specification was released originally for an automatic transmissionoil cooler hose. The hose is resistant to long term exposure toautomatic transmission fluid up to 150° C. and air temperatures up to125° C., For applications requiring air temperatures above 125° C.,consider WSD-M96D 13-A.

3. Requirements

3.1 Quality System Requirements

Material suppliers and part producers must conform to Quality SystemRequirements, QS-9000. Material specification requirements are to beused for initial qualification of materials A Control Plan for ongoingproduction verification is required. This plan must be reviewed andapproved by the relevant Ford Materials activity and/or Ford SupplierTechnical Assistance (STA) prior to production parts submissionAppropriate statistical tools must be used to analyze process/productdata and assure consistent processing of the materials.

Part producers using this material in their products, must use Fordapproved materials and must conform to a process control plan which hasbeen approved by STA and/or the relevant Materials Activity.

3.2 Infrared Spectrophotometry and/or Thermal Analysis

Ford Motor Company, at its option, may conduct infrared and/or thermalanalysis of material/parts supplied to this specification. The IRspectra and thermograms established for initial approval shallconstitute the reference standard and shall be kept on file at thedesignated material laboratory All samples shall produce IR spectra andthermograms that correspond to the reference standard when tested underthe same conditions.

3.3 Conditioning and Test Conditions

All test values indicated herein are based on material conditioned in acontrolled atmosphere of 23+/−2 C and 50+/−5% relative humidity for notless than 24 hours prior to testing and tested under the same conditionsunless otherwise specified.

3.4 Hose Construction

The hose shall consist of a smooth bore synthetic rubber tube and hightemperature and oil resistant synthetic rubber cover (see paragraph5.2). The tube shall be covered with a single ply of suitable braidedreinforced textile. The hose may be coupled with a crimped metalend-fittings.

3.5 Material Testing

The following tests shall be performed on finished hoses and/or testspecimens cut from them. The test specimens shall be die-cut from thefinished parts and buffed or slit to the required thickness wherenecessary. When not feasible, specimens cut from moulded test slabsmanufactured from the same material with an equivalent state of cureshall be used. The test slabs shall have the following dimensions:150×150 mm, min×2.0+/−0.2 mm

3.6 Original Properties

Tube Cover 3.6.1 Hardness, International 65-80 65-80 (ISO 1183, MethodA/ASTM D 1415) 3.6.2 Hardness, Durometer A 65-80 65-80 (ISO 868/ASTM D2240, instantaneous, plied-up specimen) 3.6.3 Tensile Strength, MPa, min9 9 (ISO 37/ASTM D 4123, Die C) 3.6.4 Elongation, %, min 110 200 (ASTM D412, Die C) 3.6.5 Ozone Resistance, Rating, max 0 0 (FLTM BP 101-01mProcedure A or B) 3.6.6 Compression Set, %, max 60 65 (ISO 815/ASTM D395, Method B, 70 h At 125 +/− 2 C.)

3.7 Aged Properties

3.7.1 Heat Aged, Cover Only (ISO 188/ASTM D 573, 168 h at 150 +/− 2 C.)Hardness Change 0 to +10 IRHD Tensile Strength Change, max −10%Elongation at Break Change, max −40% Visual Evaluation No surfacetackiness or cracks when folded flat against itself.

3.7.2 Heat Aged, Cover Only (ISO 188/ASTM D 573, 1000 h at 120 +/− 2 C.)Hardness Change 0 to 25 IRHD Tensile Strength Change, max −20%Elongation at Break Change, max −65% Visual Evaluation No surfacetackiness or cracks when folded flat against itself.

3.7.3 Immersion in Currently Released Production Automatic TransmissionFluid, Tube Only (ISO 1817/ASTM D 471, 168 h at 150 +/− 2 C., seeparagraph 5.1) Hardness Change 15 IRHD Tensile Strength Change, max −50%Elongation at Break Change, max −65% Volume Change 0 to +35% VisualEvaluation No surface tackiness or cracks when folded flat againstitself.

3.7.4 Immersion in Currently Released Production Automatic TransmissionFluid, Tube Only (ISO 1817/ASTM D 471, 1000 h at 135 +/− 2 C., seeparagraph 5.1) Hardness Change 15 IRHD Tensile Strength Change, max −60%Elongation at Break Change, max −85% Volume Change 0 to 35% VisualEvaluation No surface tackiness or cracks when folded flat againstitself.

3.7.5 Immersion in Oil IRM 903 (ISO 1817/ASTM D 471, 168 h at 150 +/− 2C.) Hardness Change −25 IRHD Tensile Strength Change, max −40%Elongation at Break Change, max −55% Volume Change, max 0 to +65% VisualEvaluation No surface tackiness or cracks when folded flat againstitself.

3.8 Finished Part

3.8.1 Burst Pressure, min 6.9 MPa (ASTM D 380) 3.8.2 Adhesion, min 1.4N/mm (ASTM D 413, Strip Method, Type A) 3.8.3 Tensile Strength (ASTM D380, 25 mm/minute)

This requirement applies only when couplings are used with the hose.Assemblies must withstand a minimum pull of 1.1 kN without the couplingsseparating from the hose, leakage at coupling connection or rupture ofthe hose.

3.8.4 Low Temperature Flexibility No breaks or cracks Oil Aging/ColdSoak

Test Method: Hose assembly shall be filled with current productionapproved automatic transmission fluid (see Paragraph 5.1), closed atboth ends and heat aged at 150+/−2 C for 24 h. The aged assemblies,after cooling to 23+/−2 C, shall be conditioned at −40+/−1 C for 24 h.After conditioning and while in the cold box, the hose assembly shall bebent around a temperature conditioned mandrel, having a radius equal tothe minimum bend radius of 10 times the I.D. Flexing shall beaccomplished within 4 s.

3.8.5 Accelerated Impulse Test

Test Method. Hose assemblies and/or uncouple d hose, where applicableshall be preconditioned by filling with current production approvedautomatic transmission fluid (see paragraph 5.1), closed at both endsand heat aged at 150+/−2 C for 70 h prior to impulse testing. Forinitial qualification the aged hose assemblies must withstand 250,000impulse cycles at maximum working pressure of 1.1 MPa without burstingor show any signs of failure. Hose assemblies removed from test standand burst pressure tested shall not average more than 20% below theaverage of original results per paragraph 3.8.1. Periodic certificationtesting thereafter shall require aged assemblies to withstand 100,000impulse cycles at maximum working pressure of 1.1 MPa without failurewhile maintaining temperatures of transmission fluid at 150° C. and theambient air chamber at 125° C. Burst strength values from hoseassemblies after completion of 100,000 impulse cycles shall not averagemore than 15% below the average of original results (paragraphs 3.8.1and 3.8.3),

Impulse Test Conditions: Oil Temperature 150 +/− 3 C. AmbientTemperature 125 +/− 5 C. Cycle Rate 30-40/minute Cycle Data: PressureRise Time 0.20 +/− 0.02 s High Pressure Hold Time 0.65 +/− 0.02 sPressure Drop 0.20 +/− 0.10 s Pressure Variation 0-1.10 MPa HydraulicFluid Currently Released Automatic Transmission Fluid (see para 5.1)

3.8.5.1 Oil and Heat Resistance

After successful completion of 100,000 impulse cycles according toparagraph 3.8.5, standardized ASTM specimens taken from the hose shallnot exceed the following values:

Tube Cover Hardness, Change, max −15 +15 Tensile Strength Change, % max−50 +35 Elongation at Break Change, % max −60 −65

3.8.6 Resistance to Kinking

Test Method. Insert required length of hose on test fixture securingeach end with metal clamps. When installing hose, it shall be bentwithin 5 s in the same plane and direction as its free state curvaturePlace fixture in an oven at 120+/−2 C for 1 h. Remove fixture from ovenand within 5 minutes pass a steel ball of specified diameter throughhose installed on fixture Ball must pass freely.

I.D. Test Sample Length, Typical Range min +/− 3.0 mm Ball Diameter mmmm mm 7.1-8.7 300 3.20 +/− 0.05  8.8-10.1 350 3.95 +/− 0.05 12.1-13.3450  5.5 +/− 0.05

Sample Selection: Production hose selected for the kink test shouldrepresent, as nearly as possible, minimum wall thickness. When recordingresults include wall thickness, ovality, and dimension “A” (see above).This dimension is measured while sample is on the test fixture.

The invention will be better understood by reference to the followingexamples which serve to illustrate the invention but not to limit thesame,

TABLE 1 FUNCTION OF INGREDIENTS CHEMICAL NAME INGREDIENT EXAMPLE A TyrinCM 0836 Chlorinated Polyethylene Polymer 70 Polymer-36% Cl, Mooney 100Vamac DP Ethylene/Acrylic Elastomer-High Polymer 30 levels ofmethyacrylate in polymers, composition proprietary Maglite DE MagnesiumDioxide Activator/Acid 3.5 Scavenger DHT-4A-2 Magnesium Aluminum HydroxyActivator/Acid 7.5 Carbonate Scavenger AC Poly 617A Polyethylene WaxProcess Aid 2 N990 Carbon Black Filler 135 Hubercarb Q325 CalciumCarbonate Filler 10 Paraplex G62 Epoxidized Soybean Oil Plasticizer 15Plasthall P-670 Polyester Adipate Plasticizer 27 Vulcup 40KE2,2′-bis(tert- Vulkanizing Agent 5 butylperoxydiisopropylbenzene)Trigonox 29-40B- 1-1-di(tert-butylperoxy)-3,3,5- Vulkanizing Agent 0.15PD trimethylcyclhexane TAC DLC-A Triallyl Cyanurate Co-Agent 7.5 VanaxMBM N-N′-m-phenylenedimaleimide Co-Agent 0.5 Total 313.15

EXAMPLES

The various ingredients of Table 1 were compounded in a manner as setforth above. That is all the non-curing components were added one by oneto a high shear mixer such as those made by Farrel or Krupp and blendedwith the polymers being added last. Total mixing time was generally fromabout 3 to about 10 minutes with about 4 minutes being preferred, andthe mixing temperature of the mixer was 250° F. to about 320° F. withapproximately 300° F. being preferred. After cooling and forming intoslabs, the chlorinated polyethylene composition was then mixed with theindicated curing agents at a low temperature of at about 200° F. to 250°F. and then extruded into a shape of a tube. Subsequently, the tube wascured at about 345° F. for approximately 13 minutes and tested Examples1, 3 and 4 were rubber compositions tested after various production runswhereas Example 2 was a rubber composition made in the form of a hoseand removed there from and tested. The following properties wereobtained.

TABLE 2 Example 1 Example 2 Example 3 Example 4 (Production) Off Hose(Production) (Production) WSA-M96D26-A Tensile, psi (1305 min) 1470 —1680 1620 Elongation, % (110% min) 212 175 190 193 Durometer, (65-80) 7365 73 73 50% Modulus — — 420 404 Compression Set, Plied — — — — 70 hrs.at 125° C., 60% max 61 54.1 60.7 61.6 ATF-D, 168 hours at 150 C. TensileChange, % (−50% max.) −3 3 0 5 Elongation Change, % (−65% −37 −23 −22−25 max.) Hardness Change, (−15 pts. −2 −11 −1 −1 Max.) % Volume Change,0/+35% 8.3 7 9.4 8.2 ATF-E, 168 hours at 150 C. 8 14 5 32 TensileChange, % (−50% max.) −60 −62 −51 −52 Elongation Change, % (−65% 9 −2 912 max.) Hardness Change, (−15 pts. 9.9 6.1 10.7 9.2 Max.) % VolumeChange, 0/+35% — — 1082 1218 50% Modulus 8 14 5 32 IRM 903 Oil, 168hours at 150 C. Tensile Change, % (−40% max.) 8 14 5 32 ElongationChange, % (−55% −60 −62 −51 −52 max.) Hardness Change, (−25 pts. 9 −2 912 Max.) % Volume Change, 0/+65% 9.9 6.1 10.7 9.2

Examples 1 through 4 gave excellent results with respect to low changein various properties such as tensile strength, elongation, hardness,and percent volume at high temperatures. Moreover, such tubing passedthe “E” type transmission fluids tests.

High Heat Resistant Rubber Compositions

The formulations of the high heat resistant rubber compositions arebased upon 70 parts by weight of one or more chlorinated polyethyleneelastomers. The amount of chlorine in the elastomer is generally fromabout 20% to about 45% by weight, and preferably from about 25% to about30% by weight. If two or more different chlorinated polyethyleneelastomers are utilized, the amount of one of the elastomers isgenerally from about 1% to about 99% and desirably from about 25% toabout 75% by weight based upon the total weight of the chlorinatedpolyethylene elastomers. Such elastomers are known to the art and to theliterature. Examples of such suitable chlorinated polyethyleneelastomers include Tyrin CM 0730 which contains about 30% by weight ofchlorine and has a Mooney viscosity (ML 1+4/100° C.) of about 65, TyrinCM 0836 which contains about 36% by weight of chlorine and has a Mooneyviscosity of about 100, and Tyrin CM 0136 which contains about 36% byweight of chlorine and has a Mooney viscosity of about 80. The Tyrinchlorinated polyethylene elastomers are produced by DuPont Dow.

An important aspect of the present invention is to utilize anethylene-octene copolymer in an amount of from about 5 to about 49 partsby weight, desirably from about 12 to about 30 and preferably from about10 to about 20 parts by weight per 70 parts by weight of the one or morechlorinated polyethylene elastomers. Such copolymers generally containfrom about 25% to about 55% by weight and desirably from about 35% toabout 45% by weight of the octene unit, Desirably the copolymers have alow specific gravity of from about 08.5 to about 08.7 and have a meltindex of from about 0.25 to about 5.0 dg/min. Such copolymers areavailable as the Engaged polymers produced by DuPont Dow such as EngagedCL 8001, Engaged CL 8002, Engaged EG 8200, and preferably Engaged EG8150.

An important component utilized to form the high heat resistance rubbercomposition generally comprise one or more ethylene-acrylic elastomerswherein the acrylic portion can be an alkyl acrylate wherein the alkyldesirably has from about 1 to about 8 carbon atoms and preferably ismethyl acrylate. The ethyleneacrylic elastomers generally have a Mooneyviscosity of from about 10 to about 25 and preferably from about 13 toabout 19. The total amount of the one or more ethylene-acrylicelastomers is generally from about 5 to about 49 parts, desirably fromabout 5 to about 35 parts, and preferably from about 10 to about 30parts by weight per 70 parts by weight of said one or more chlorinatedpolyethylene elastomers. Examples of suitable elastomers include VamacD, Vamac DLS, Vamac G, Vamac GLS, and Vamac HG with Vamac DP beinghighly preferred.

In lieu of the ethylene-acrylic elastomer or in any portion therewith,one or more polyacrylate elastomers can be utilized which are known tothe art and to the literature. Generally, polyacrylate elastomerscontain repeat units of alkyl acrylates wherein the alkyl portiondesirably has from 1 to about 8 carbon atoms, and preferably is methylacrylate or ethyl acrylate. Generally lesser amounts of alkoxy acrylatesare also utilized wherein the alkoxy portion generally has from 1 to 5carbon atoms with methoxy or ethoxy being preferred. The Mooneyviscosity of the one or more acrylate elastomers is generally from about10 to about 70 and preferably from about 25 to about 4 or 55. The amountof the polyacrylic elastomers is generally from about 5 to about 49parts, desirably from about 5 to about 35 parts, and preferably fromabout 10 to about 30 parts by weight per 70 parts by weight of saidchlorinated polyethylene elastomers. The polyacrylic elastomer can beutilized either in lieu of the one or more ethylene-acrylic elastomersor partially substituted therefore. In other words, any combination ofthe ethylene-acrylic elastomers or the polyacrylic elastomers can beutilized with the total amount of both being from about 5 to about 49parts by weight, desirably from about 5 to about 35 parts by weight andpreferably from about 10 to about 30 parts by weight per 70 parts byweight of said polychlorinated polyethylene elastomers. Inasmuch as thepresent invention generally relates to peroxide cure, polyacrylates areutilized which are curable by a peroxide. Since the polyacrylates have asaturated backbone, crosslinking is accomplished via incorporation of aco-polymerized reactive cure site such as through the use of suitableperoxide reactive compounds such as a carboxylic acid, and the like. Asuitable polyacrylic elastomer is HyTemp PV-04 made by Zeon Chemicals.

An optional component of the high heat resistant rubber composition arevarious EPDM polymers wherein the amount of ethylene repeat groups isgenerally from about 30% to about 70% and preferably from about 35% toabout 60% by weight, and wherein the amount of diene is generally fromabout 0.1 to about 8% and desirably from about 0.2% to about 2% byweight based upon the total weight of the copolymer. The amount of theEPDM rubber is generally from about 10 to about 50 parts by weight,desirably from about 12 to about 35 parts by weight and preferably fromabout 15 to about 25 parts by weight per 70 parts by weight of the oneor more chlorinated polyethylene elastomers A preferred commercialexample of such as compound is Nordel IP NDR-125 produced by R. T.Vanderbilt.

An optional component of the chlorinated rubber composition is achlorosulfonated polyethylene which generally contains from about 25% toabout 45%, desirably from about 30% to about 40% and preferably fromabout 33% to about 38% by weight of chlorine therein. The amount ofsulfur is generally very low as from about 0.25% to about 2%, desirablyfrom about 0.5% to about 15%, and preferably from about 0.75% to about1.25% by weight based upon the total weight of the chlorosulfonatedpolyethylene. One or more chlorosulfonated polyethylenes when utilizedis generally from about 5 to about 49 parts by weight, desirably fromabout 10 to about 40, and preferably from about 25 to about 35 parts byweight per 70 parts by weight of said one or more chlorinatedpolyethylene elastomers. Examples of such suitable compounds include thevarious Hypalon compounds from DuPont Dow such as Hypalon 20, Hypalon30, with Hypalon 40 being preferred which contains approximately 35%chlorine by weight and approximately 1% sulfur by weight.

One or more antioxidants are utilized to help impart high heatresistance to the composition. Numerous antioxidants exist and the sameare known to the art and to the literature. Specific preferred examplesof such compounds include Tetrakis [methylene(3,5-di-t-butyl-4-hydroxylhydrocinnamate)] methane mixed withPentaerythritol tris ester and3-(3,5-di-(tert)-butyl-4-hydroxyphenyl)proionic acid; ThiodiethyleneBis(3,5-Di(tert)-Butyl-4-hydroxyhydrocinnamate, and the like. The totalamount of such one or more compounds is generally from about 0.1 toabout 4, and preferably from about 0.5 to about 2 parts by weight per 70total parts by weight of the one or more chlorinated polyethyleneelastomers. Commercial examples of such antioxidants include Irganox1010 and Irganox 1035 produced by Ciba Specialty Chemicals.

The high heat resistant rubber compositions can generally containconventional additives known to the art and to the literature. Suchadditives can be the same as set forth above, that is various activatorsand/or acid scavengers, processing aids, various fillers which alsoserve as reinforcing aids, plasticizers, vulcanizing compounds andco-agents such as activators, lubricants, stabilizers, and the like.Since the description of such additives is set forth hereinabove withrespect to the chlorinated rubber fluid resistant compositions, they arehereby fully incorporated by reference. Generally the same types ofadditives can be utilized and the amounts of the various additives aregenerally the same. However, with respect to carbon black, generally asmaller amount is utilized as from about 40 to about 200 parts byweight, and desirably from about 70 to about 150 parts by weight per 70parts by weight of the one or more chlorinated polyethylene elastomers.Moreover, the amount of the calcium carbonate fillers is generally fromabout 5 to about 50 parts by weight and desirably from about 10 to about40 parts by weight per 70 parts by weight of the one or more chlorinatedpolyethylene elastomers.

Various vulcanizing agents as well as co-agents (accelerators) can beutilized Numerous such compounds exist and are known to the art and tothe literature. With respect to specific chemical examples and specificcommercial examples, generally the same compounds can be utilized as setforth above with regard to the chlorinated rubber compositions andgenerally the same amounts of the vulcanizing agents and co-agents canbe utilized. Accordingly, they are hereby fully incorporated byreference.

A preferred end use of the present invention is to co-extrude the highheat resistant rubber composition about the chlorinated polyethylenerubber fluid resistant composition in the form of a tube to form alaminated tube, hose, or the like. In order to impart strength to thehose, reinforcing fibers, either non-woven or preferably woven, can beused.

A preferred end use is a formation of a hose for use with a vehicleautomatic transmission fluid such as the above noted F-type fluid.

The invention will be better understood by reference to the followingexample which serves to illustrate but not to limit the presentinvention.

In formation of the high heat resistant rubber composition of Table 3,the various additives are added in any order, one by one to a high shearmixer followed by the addition of the various polymers, as for exampleone at a time, and mixed at a suitable temperature and time to achieve ablend of a high heat resistant rubber composition. The compoundingprocedure is essentially the same as set forth above with regard to thechlorinated polyethylene rubber fluid resistant composition. Thus, thehigh shear mixer utilized can be the same. The mixing temperature of thehigh shear mixer with respect to the high heat resistant rubbercomposition is generally from about 250° F. to about 230° F. with about300° F. being preferred and the mixing time can vary from about 3 toabout 10 minutes with about 4 minutes being preferred. As before, oncethe composition is blended, it can be cooled and stored. At somesubsequent time, the one or more vulcanizing agents and co-agents areadded and mixed at a low temperature such as at about 200° F. to about250° F. so as not to cure the rubber.

Once it is desired to form an end product, the high heat resistantrubber compositions containing the curing compounds therein can be mixedat a higher temperature and formed or shaped into a suitable end productand cured as at a temperature of from about 330° F. to about 360° F. forabout 10 to about 18 minutes Suitable end products include sheets,jackets on existing tubing or hoses, seals, and the like.

TABLE 3 Function of INGREDIENTS Chemical Name Ingredient Example A TyrinCM 0730 Chlorinated Polyethylene Polymer-30% Polymer 70 Cl, Mooney 65Engage 8150 Ethylene-Octene Polymer-39% Polymer 15 Comonomer, 868 sp.Gravity, Melt Index 0.5 dg/min Vamac DP Ethylene/Acrylic Dipolymer-Highlevels of Polymer 15 methyacrylate in polymers, composition proprietaryMaglite DE Magnesium Dioxide Activator/ 3.5 Acid Scavenger AC Poly 617APolyethylene Wax Processing 2 Aid Irganox 1010 Tetrakis [methylene(3,5-di-t-butyl-4- Antioxidant 1 hydroxyhydrocinnamate)] methane mixedwith Pentaerythritol tris ester and 3-(3,5-di-(tert)-butyl-4-hydroxyphenyl) proionic acid DHT-4A-2 MagnesiumAluminum Hydroxy Carbonate Activator/ 7.5 Acid Scavenger N990 CarbonBlack Filler 90 Hubercarb Q325 Calcium Carbonate Filler 20 Paraplex G62Epoxidized Soybean Oil Plasticizer 11 TOTM Trioctyl TrimellitatePlasticizer 11 Nordel IP NDR- Ethylene-Propylene-Diene Terpolymer-Polymer/ 20 125 42.5% Ethylene, 0.5% Diene Plasticizer Vulcup 40KE2,2′-bis(tert- Vulkanizing 4.5 butylperoxydiisopropylbenzene) Agent.Trigonox 29-40B- 1-1-di(tert-butylperoxy)-3,3,5- Vulkanizing 0.15 PDtrimethylcyclhexane Agent Ricon 152 DLC 1,2-Polybutadiene dispersed onCalcium Co-Agent 8 70% Silicate TAC DLC-A Triallyl Cyanurate Co-Agent4.5 Vanax MBM N-N′-m-phenylenedimaleimide Co-Agent 0.75 Total 283.90

When the high heat resistant rubber composition was prepared, andtested, the following data was obtained

TABLE 4 Chemical Function of INGREDIENTS Name Ingredient Example AWSA-M96D26-A Tensile, psi (1305 1790 min) Elongation, % 230 (110% min)Durometer, (65-80) 78 70 hrs. at 125° C., 42.8 65% Max Tensile Change, %10 (−10% max.) Elongation Change, % −21 (−40% max.) Hardness Change, 7pts. (+10 pts.) Ozone, D518-99, pass Conditioned for 24 hrs.

As apparent from the above data, the high heat chlorinated polyethylenerubber composition had small changes in various properties such astensile strength, elongation and hardness when tested 168 hours at 150°C.

While in accordance with the patent statutes the best mode and preferredembodiment have been set forth, the scope of the invention is notintended to be limited thereto, but only by the scope of the attachedclaims.

1-14. (canceled)
 15. A high heat resistant rubber composition,comprising: at least one chlorinated polyethylene elastomer comprisingfrom about 20% to about 45% chlorine by weight, the total amount of thechlorinated polyethylene elastomer being about 70 parts by weight; atleast one ethylene-octene copolymer comprising an octene content of fromabout 25% to about 55% by weight, the amount of the ethylene-octenecopolymer being from about 5 to about 49 parts by weight per 70 parts byweight of the chlorinated polyethylene elastomer, and at least oneethylene-acrylic elastomer having a Mooney viscosity of from about 10 toabout 25 and/or at least one polyacrylic elastomer having a Mooneyviscosity of from about 10 to about 70, the total amount of theethylene-acrylic elastomer and/or the polyacrylic elastomers elastomerbeing from about 5 to about 49 parts by weight per 70 parts by weight ofthe chlorinated polyethylene elastomer.
 16. The high heat resistantrubber composition of claim 15, wherein the amount of theethylene-acrylic elastomer and/or the polyacrylic elastomer is fromabout 5 to about 35 parts by weight per 70 parts by weight of thechlorinated polyethylene elastomer.
 17. The high heat resistant rubbercomposition according to of claim 15, wherein the ethylene-acrylicelastomer has a Mooney viscosity of from about 13 to about
 19. 18. Thehigh heat resistant rubber composition of claim 15, wherein thechlorinated polyethylene elastomer comprises from about 25% to about 40%chlorine by weight, and wherein the ethylene-octene copolymer comprisesan octene content of from about 35% to about 45% by weight.
 19. The highheat resistant rubber composition of claim 31, wherein the amount of theEPDM rubber is from about 12 to about 35 parts by weight per 70 parts byweight of the chlorinated polyethylene elastomer, the EPDM rubbercomprising an ethylene content of from about 35% to about 60% by weightand comprising a diene content of from about 0.2% to about 2% by weight.20. The high heat resistant rubber composition of claim 15, furthercomprising from about 5 to about 49 parts by weight of achlorosulfonated polyethylene elastomer per 70 parts by weight of thechlorinated polyethylene elastomer, the chlorosulfonated polyethyleneelastomer comprising from about 25% to about 45% by weight of chlorineand from about 0.25% to about 2% by weight of sulfur.
 21. The cured highheat resistant rubber composition of claim
 15. 22-28. (canceled)
 29. Thehigh heat resistant rubber composition of claim 15, wherein thepolyacrylic elastomer has a Mooney viscosity of from about 25 to about55.
 30. The high heat resistant rubber composition of claim 15, furthercomprising: an antioxidant in an amount of from about 0-1 to about 4parts by weight per 70 parts by weight of the chlorinated polyethyleneelastomer; and a carbon black in the amount of from about 40 to about200 parts by weight per 70 parts by weight of the chlorinatedpolyethylene elastomer.
 31. The high heat resistant rubber compositionof claim 15, further comprising at least one EPDM rubber comprising: anethylene content of from about 30% to about 70% by weight; and a dienecontent of from about 0.1% to about 8% by weight, wherein the amount ofthe EPDM rubber is from about 10 to about 50 parts by weight per 70parts by weight of the chlorinated polyethylene elastomer.
 32. The highheat resistant rubber composition of claim 31, wherein the amount of theethylene-octene copolymer is from about 10 to about 20 parts by weightper 70 parts by weight of the chlorinated polyethylene elastomer, andwherein the amount of the ethylene-acrylic elastomer and/or thepolyacrylic elastomer is from about 10 to about 30 parts by weight per70 parts by weight of the chlorinated polyethylene elastomer.
 33. Acomposition, comprising: a chlorinated polyethylene elastomer having aMooney viscosity of from about 65 to about 80, the total amount of thechlorinated polyethylene elastomer being about 70 parts by weight; anethylene-octene co-polymer in an amount of from about 10 to about 20parts by weight per 70 parts by weight of the chlorinated polyethyleneelastomer; and an ethylene-acrylic elastomer in an amount of from about5 to about 40 parts by weight per 70 parts by weight of the chlorinatedpolyethylene elastomer.
 34. The composition of claim 33, wherein thechlorinated polyethylene elastomer comprises from about 25% to about 50%chlorine by weight.
 35. The composition of claim 33, wherein thechlorinated polyethylene elastomer comprises from about 30% to about 36%chlorine by weight.
 36. The composition of claim 33, wherein thechlorinated polyethylene elastomer comprises about 30% chlorine byweight.
 37. The composition of claim 33, wherein the chlorinatedpolyethylene elastomer has a Mooney viscosity of about
 65. 38. Thecomposition of claim 33, wherein the amount of the ethylene-octenecopolymer is about 15 parts by weight per 70 parts by weight of thechlorinated polyethylene elastomer.
 39. The composition of claim 33,wherein the ethylene-octene copolymer comprises an octene content offrom about 35% to about 45% by weight.
 40. The composition of claim 33,wherein the ethylene-octene copolymer comprises an octene content ofabout 39% by weight.
 41. The composition of claim 33, wherein theethylene-octene copolymer has a specific gravity of from about 0.85 toabout 0.87.
 42. The composition of claim 33, wherein the ethylene-octenecopolymer has a specific gravity of about 0.868.
 43. The composition ofclaim 33, wherein the ethylene-octene copolymer has a melt index of fromabout 0.25 to about 5 dg/min.
 44. The composition of claim 33, whereinthe ethylene-octene copolymer has a melt index of about 0.5 dg/min. 45.The composition of claim 33, wherein the amount of the ethylene-acrylicelastomer is about 15 parts by weight per 70 parts by weight of thechlorinated polyethylene elastomer.
 46. The composition of claim 33,wherein the ethylene-acrylic elastomer has a Mooney viscosity of fromabout 10 to about
 25. 47. The composition of claim 33, wherein theethylene-acrylic elastomer comprises an ethylene-methacrylic elastomers.48. The composition of claim 33, further comprising an ethylenepropylene diene monomer rubber comprising: an ethylene content of fromabout 30% to about 70% by weight; and a diene content of from about 0.1%to about 8% by weight, wherein the amount of the ethylene propylenediene monomer rubber is from about 10 to about 50 parts by weight per 70parts by weight of the chlorinated polyethylene elastomer.
 49. Thecomposition of claim 33, further comprising from about 5 to about 49parts by weight of a chlorosulfonated polyethylene elastomer per 70parts by weight of the chlorinated polyethylene elastomer, thechlorosulfonated polyethylene elastomer comprising from about 25% toabout 45% chlorine by weight and from about 0.25% to about 2% sulfur byweight.
 50. The cured composition of claim
 33. 51. The cured compositionof claim
 48. 52. The cured composition of claim 49.